Dual format adhesive apparatus for intermittently disrupting parallel, straight lines of adhesive to form a band

ABSTRACT

A laminate is made by applying a plurality of parallel fine lines of adhesive to a first web, intermittently agitating the adhesive prior to deposition to intermingle the adhesive to form spaced apart bands extending across the fine lines, and then applying a second web over the adhesive to join the webs together. The intermittent cross bands prevent migration of particles and leakage along said fine lines. When diapers are made from the laminate, waistbands are formed in the areas of the cross bands. Apparatus is disclosed.

This invention relates to adhesive application for lamination and more particularly to adhesive applicators and methods for improved adhesive application and products.

It is well known to adhere two webs or sheets together by applying parallel beads or fine lines of adhesives to one web or sheet and then combining the two webs or sheets so the adhesive can bind them together. One use of this technique is found in the manufacture of disposable diapers. These usually include a moisture impervious polyethylene backing, and a non-woven, absorbent pad sometimes referred to as "fluff".

In making such diapers, parallel beads or fine lines of adhesive are deposited in a machine direction onto a moving web of polyethylene backing material. The non-woven web or fluff is laid on the plastic web so the elongated adhesive beads secure it to the backing. Leg holes are then cut in the laminate and the diaper is otherwise finished. Such a technique is described in U.S. Pat. No. 4,874,451, which is incorporated herein by reference.

One of the difficulties in using such a technique in manufacturing diapers is that the adhesive beads tend to define channels on the polyethylene backing. Particles of super absorbent non-woven material can migrate through these channels to the diaper's leg holes or waist areas where they escape. The channels may lead to other problems such as leaking. Additional manufacturing treatment or components are required to seal off these channels.

It is also known in the diaper manufacturing industry to apply the adhesive to the plastic backing web in a "swirl" pattern, or in random "fibrous" depositions. Overlapping swirls could be applied, for example, by apparatus such as that disclosed in U.S. Pat. No. 4,983,109 which is incorporated herein by reference. Such swirl or fibrous adhesive applications provide a more "homogeneous" or continuous adhesive blanket and do not create the channels noted above. They thus provide continuous adhesion, both in the machine direction and in the cross-machine direction across the backing. This inhibits moisture leaking or particle migration. Also, these processes permit cooler deposition of hot melt adhesives on the plastic backing, thus avoiding burn through. Accordingly, the gage of the backing can be reduced, with attendant cost savings.

Nevertheless, the parallel bead process does provide certain beneficial adherence and process characteristics not obtained by the "swirling" process. For example, the beads remain at a somewhat higher temperature when applied and in certain applications generate greater adhesion or bonding strength. These characteristics will continue to be desirable in certain diaper applications, disposable pads, and in other products. There is a continuing need, however, to prevent migration of moisture and particles along the beads, i.e. along the length or in the machine direction of the product.

Accordingly, it is one objective of this invention to provide an improved fine line adhesive application which prevents moisture or particle migration to undesirable outlets at the line ends.

A further objective of the invention has been to provide apparatus for applying an improved adhesive application to a substrate.

A further objective of the invention has been to provide an improved article comprising a flexible backing sheet and an absorbent pad adhered thereto with fine lines of adhesive.

A further objective has been to provide an improved method for securing fluff to a flexible backing.

A further objective of the invention has been to provide an improved method for adhering one substrate to another.

A further objective of the invention has been to provide an improved method for applying adhesive to a substrate.

To these ends, a preferred embodiment of the invention includes an adhesive application comprising a plurality of parallel beads or fine line deposition of adhesive along a substrate in a machine direction, and a swirl pattern or random fibrous adhesive deposition in a cross-machine direction on the substrate at intermittent, selected distances along the fine line deposition. The swirl or fibrous deposition joins the fine lines and provides a migration barrier across the fine lines.

A fine line applicator, having a plurality of fine line or elongated bead producing nozzles, is provided with air jet means associated with each nozzle. These are intermittently activated to selectively swirl or disrupt the emanating bead into a swirl pattern or into a random fibrous orientation, thus producing a homogeneous or continuous adhesive band across the fine lines. This band serves as a barrier to migration along the lines.

An air source is selectively controlled so as to discontinue air flow to the air jet means when fine parallel lines are to be deposited, and to supply air flow at selected times when desired to produce a transverse band of swirl pattern or random fibrous adhesive to seal off the fine lines.

These sealing bands are produced, for example, in the areas which will respectively form the leg holes or waist of a diaper to prevent migration of moisture or particles from between the backing and the fluff. At the same time, the enhanced bonding characteristics of the fine line adhesive are attained, yet without the need to otherwise treat or apply additional components to stop deleterious migration.

Accordingly, a fine line applicator for depositing fine lines of adhesives is provided with cyclic air jet means to produce swirls or fibrous depositions cross-joining the fine lines at selected intermittent locations.

The invention provides advantages of both prior and previously exclusive techniques, i.e. the adhesion benefits of fine line deposition with the migration preventing continuous adhesive blanket deposition.

These and other advantages will become readily apparent from the following description of a preferred embodiment of the invention and from the drawings in which:

FIG. 1 is a perspective view of an adhesive application process, application apparatus and article according the invention;

FIG. 1A is a diagrammatic end view of the adhesive applicator of FIG. 1 illustrating fine line adhesive deposition;

Fig. 1B is a diagrammatic end view of the adhesive applicator of FIG. 1 illustrating adhesive swirl or random fibrous deposition;

FIG. 2 is a schematic elevational end view of the adhesive applicator taken along lines 2--2 of FIG. 1;

FIG. 3 is a view similar to FIG. 2 but showing the fine line producing grooves in the adhesive applicator; and

FIG. 4 is an enlarged cross-sectional view taken along lines 4--4 of FIG. 2 and illustrating also an adhesive receiving substrate.

SPECIFICATION

Turning now to the drawings, it will be appreciated that the invention contemplates improved methods and apparatus for producing an improved laminate structure, particularly useful in the manufacture of disposable products, such as absorbent diapers, pads and other similar products. The manufacturing process for the laminate is diagrammatically illustrated in FIG. 1.

An applicator head 10 is operable to supply adhesive to one side of an elongated web comprising a flexible backing 11, such as a thin, moisture impervious, polyethyene film. The moving web is then rolled through a nip at 12, where a web 13 of absorbent fluff material is combined with the backing web, such that the adhesive holds the two webs together. Thereafter, the combined moving laminate 14 is conveyed in a machine direction to a cutting platen 15. A knife 16 severs the laminate within the area defined by crossbands of adhesive as will be described. While the laminate 14 and the cut-off articles 17 are shown in FIG. 1 as being rectangular, it will be appreciated they could be of other longitudinal shapes, such as diapers with cut out leg holes or other pad configurations or the like.

It will also be appreciated that the fluff 13 is preferably a non-woven, absorbent material, such as that utilized in disposable diapers, for example, but could be other forms of material, depending on the desired application.

The invention contemplates the application of adhesive by the applicator head 10 onto the first web or substrate 11, primarily in a plurality of fine lines of adhesive 20, as shown in FIG. 1. These are deposited onto the substrate 11 from a slot die nozzle 21. Adhesive emanates from the slot die 21 in the form of a plurality of adhesive beads, such as at 22 (see Fig. 1a). When the beads contact the moving substrate 11 thereunder, they are deposited on that substrate in the form of a plurality of parallel, fine lines of adhesive 20.

It will be appreciated, as used above, the term "beads" is used for descriptive purposes in this application to refer to the adhesive emanating from the slot die nozzle 21 in the area between the slot die nozzle and the substrate 11. On the other hand, the term "fine line" is used generally in this application to describe the adhesive as it is deposited on the underlying substrate 11. This distinction is made in this application for the purpose of description only. It will be appreciated that the elongated parallel strips of adhesive on the substrate 11 could also be referred to as beads of adhesive on the substrate.

The slot die nozzle 21 is provided with means for intermittently agitating the beads 22 (FIG. 1A) into a swirl or a random fibrous pattern, as illustrated diagrammatically in Fig. 1B. Such agitated beads are diagrammatically indicated at 23 in Fig. 1B. When the beads are agitated, they still descend to, and are deposited on the substrate 11, but not in the form of parallel fine lines of adhesives. Instead, the agitated beads commingle in a swirl pattern or in a random fibrous orientation. Such swirl or random fibrous lines constitute a continuation of the fine parallel lines, but are intermingled with each other so as to join the adjacent parallel fine lines in a band of adhesive 24. Such bands are selectively and intermittently spaced in the cross machine direction, i.e. across the web 11, transversely to the machine direction.

When the beads 22 are deposited in parallel, fine lines on the substrate 11, the parallel fine lines 20 are spaced apart and define channels therebetween. Nevertheless, the intermingling of agitated beads 23 in the swirl or fibrous pattern of the band 24 seals off the spaces or channels between the fine lines 20 so that no particles of fluff material or other particles can migrate along those fine lines past the band 24. Accordingly, the bands of adhesive 24 serve to interrupt any migration of particles along the substrate 11 in the areas between the fine lines 20 of adhesive.

It will be appreciated that when the laminate 14 is cut by knife 16, that cut is disposed within the band 24, so that each end of the separated laminates 17 have an edge band of intermingled swirled or fibrous adhesive extending in a cross machine direction across the ends of the fine lines 20. This interrupts any migration of particles between the fine lines 20 outwardly at the edge 18 of the cut-off laminates 17.

It will also be appreciated that when the adhesive beads emanating from the nozzle 21 are swirled or otherwise agitated to form a random fibrous pattern, they still constitute a continuation of the lines of adhesive which are already laid down on the substrate 11, so that a migration barrier is formed by that band across the adhesive lines.

Turning now to a further description of the apparatus for producing the parallel fine lines of adhesives with the intermittent cross bands, reference is made to FIG. 2, which constitutes a diagrammatic elevational end view of the adhesive applicator 10. The applicator 10 includes a head 30 and a slot die 21. With the exception of the details of FIG. 4, the applicator 10 is essentially like that described in detail in U.S. Pat. No.4,874,451. Reference is also made to U.S. Pat. No. 3,825,379 and the melt blowing die disclosed therein.

The slot die 21 includes a plurality of adhesive grooves or nozzles 31, defined by complimentary relieved areas in die halves 32 and 33. The adhesive outlet grooves 31 may be ganged in sections, such as sections 34, 35 (FIGS. 2 and 3) for the generation of a plurality of adhesive beads. These sections can be controlled independently, as described in U.S. Pat. No. 4,874,451 for particular applications.

Each section 34, 35 is fed by a respective inlet passage such as at 36 or 37. Adhesive is conveyed from an adhesive control valve, such as 38, 39, 40 or 41, to respective sections also as described in U.S. Pat. No. 4,874,451. Valves 40, 41 feed respective sections 34, 35 shown herein. The inlets 36, 37 feed respective triangular portions 42 or 43 for distribution of adhesive to the adhesive outlets 31. Referring to FIGS. 3 and 4 then, each of the sections of adhesive emanating grooves 31 are fed by a respective triangular section 42, 43. Inlets 36 and 37 feed the triangular relieved areas 42 and 43. The inlets are also connected to the runners or passages 51, 52.

The valves 38-41 are operated through a valve air manifold 45 by one or more air solenoids 46-48, as described in the preceding U.S. Pat. No. 4,874,451. Recirculation valves 49 and 50 are used as described in said patent for adhesive control when the outside sections or banks of orifices are to be shut off, such as when the underlying substrate moving under the slot die is in an area corresponding to the position where leg holes will be cut out from the resulting diapers.

It will be appreciated that the valves 38-41 are appropriately connected via manifolds and passages to control circuits for operating the valves, such as air passages, and to adhesive manifolds for selective control of adhesive flow to the sections of adhesive emanating grooves or nozzles.

The slot die 21, according to the invention, is provided with air jet means 55, 56, defined as elongated passageways in manifold covers 57 and 58. Air chambers 59 and 60 are interconnected to a source of pressurized air 61 through a pneumatic line 62. Pressurized air source 61 is controlled by an electric or pneumatic solenoid controller means 63 of any suitable type for operating the air source to selectively pressurize line 62 and chambers 59 and 60 with pressurized air. When pressurized, this causes a flow of air through the air jet means or passages 55, 56, to impinge on a bead of adhesive 23 emanating from the outlet 31 (Fig. 1B) to agitate that adhesive bead and cause it to form a swirl or spiral, or to be deposited in a random fibrous orientation across the substrate 11 in a band of adhesive 24, such as shown in FIG. 1. It should be appreciated that the air jet means 55, 56 impinge tangentially on the bead in one form, and may themselves be angularly oriented, such that their axes do not intersect, but are directed to cause the bead to form a spiral such as, for example, the air jets in U.S. Pat. No. 4,983,109.

Of course, the air jet means 55, 56 can be provided in any suitable orientation to cause the desired swirl or agitation to produce a random fibrous pattern in a cross band, as illustrated in FIG. 1. For example, air jet means such as that described in U.S. Pat. No. 4,815,660, U.S. Pat. No. Re. 33,481, or in applicant's co-pending application Ser. No. 07/783,989 filed Oct. 29, 1991, could be used. Also, any other form of means to selectively intermittently agitate the adhesive emanating from the outlet 31 to cause it to deposit to seal off the gaps between the lines on the underlying substrate could be used. For example, a cone-shaped air passage with vanes for swirling the air and surrounding the adhesive orifice could be used, as well as elongated air slots or other means.

It will be appreciated that the band of adhesive, which is deposited on the substrate 11 when the air jets are operated, is in the cross machine or transverse direction across the substrate. The agitated beads themselves are simply a continuation of the adhesive lines which are already deposited on the substrate. The swirls or fibrous pattern in the band 24 intermingle with adjacent adhesive beads and/or lines of adhesive on the substrate, so as to bridge the spaces or distances between the parallel fine lines of adhesive, which were being deposited before the flow of air was initiated, in order to close off any spaces between those fine lines. In the deposited pattern, this interrupts any migration of particles along those fine lines between the adhered laminate substrates 11 and 13.

Of course, it will also be appreciated that the control means 63 is operated to intermittently pressurize the chambers 59, 60, to intermittently cause air flow through the air jet means 55, 56. The timing of these intermittent applications of air to the bead from the jets 55, 56, is predetermined so that the generation of the bands 24 in the cross machine direction on the substrate 11 are deposited in those areas of the substrate which will be cut by the knife 16 (FIG. 1).

Also it will be appreciated that such transverse or cross machine direction bands can be generated at other predetermined positions. When diapers are made, for example, these bands can be oriented in the areas surrounding the web material where the leg holes are to be cut. This interrupts migration of particles outside the edge of the laminate at those particular areas.

Accordingly, it will be appreciated that the invention provides apparatus and methods for depositing a predetermined adhesive on a substrate and for producing a laminate of two substrates with an improved adhesive disposition therebetween.

Accordingly, one substrate is adhered to the flexible backing substrate 11 by means of elongated, parallel fine lines of adhesive, which produce excellent bonding characteristics of the one substrate to the other, while at the same time the intermittently spaced bands 24 serve to join the elongated adhesive lines and to interrupt any migration or particles therealong. Manufacturing, cutting or other processes can be carried out in the area in which the bands 24 are deposited, to prevent the migration of particles of non-woven material of the substrate 13, for example, outside the edge of the finished laminate article at the edge. Accordingly, the article exhibits good bonding characteristics provided by a parallel fine line adhesive process, without the disadvantage of particle migration or the necessity to conduct other further manufacturing techniques or add additional elements to the laminate.

It will be appreciated that the structure of the slot die can be like that as shown in U.S. Pat. No. 3,825,379, with the appropriate slot widths to produce the desired fine lines of adhesive on an underlying substrate when the air is turned off, according to the invention herein.

It will also be appreciated that the invention is useful in a system, such as that disclosed in U.S. Pat. No. 4,874,451, where it is desired to provide a band of adhesive in the cross machine direction to join or seal off the ends of the fine line adhesive applied to the substrate. This occurs in one application such as diapers, in the areas to comprise the waistband and the leg holes of the diapers.

Accordingly, the invention provides for the realization of the greater adhesive and bonding characteristics of the fine line adhesive deposition process, but also provides the benefits of the swirl or random fibrous pattern process all in the same laminate by selectively controlling the application of air to the slot dies which are operable to emanate a bead for fine line deposition. The swirl or random fibrous bands can be created at any predetermined areas on the substrate. Moreover, instead of being continuous across the substrate, such bands could be formed in any pre-selected length by separating the air chambers 59 and 60,and dedicating them respectively to air jets serving each groove 31. With appropriate valving, this can be used to cause the bead emanating from that groove to swirl or move randomly, or to deposit in a straight line. Finally, it will be appreciated that while the swirl pattern or a random fibrous orientation may be preferred, either is possible, depending upon the orientation of the air jets 55, 56 and the nature of the air jet flow. Other forms of intermittent agitation, such as mechanical or other expedients, could be utilized as well to cause the emanating beads to intermingle, at least as deposited on the substrate, to produce the band 24, as described herein.

Accordingly, these and other modifications and advantages will be readily apparent to one of ordinary skill without departing from the scope of the invention, and the applicant intends to be bound only by the claims appended hereto: 

I claim:
 1. In an apparatus for applying adhesive to a substrate for adherence to another substrate, said apparatus including:a plurality of adhesive nozzle means for producing a plurality of emanating adhesive beads for deposition in a pattern of straight parallel lines on a first substrate; at least one air jet means in operative orientation with respect to said nozzle means for impinging a flow of air on said emanating beads; a source or pressurized air intermittently connectable to said air jet means; said air jet means, when said air flows therefrom, being operable to disturb said beads so that they intermingle laterally to form an adhesive band on said first substrate across the entire pattern said lines.
 2. Apparatus as in claim 1 further including means to combine a second substrate onto said adhesive lines and bands on said first substrate.
 3. In an apparatus for applying adhesive in varying deposition format to substrate, for adherence to another substrate, so as to interrupt channels formed between said substrates by adhesive said apparatus including apparatus:a plurality of adhesive nozzle means for producing a plurality of emanating adhesive beads for deposition in a pattern of straight parallel lines on a first substrate; air jet means in operative orientation with respect to said nozzle means for impinging a flow of air on said emanating beads; a source of pressurized air intermittently connectable to said air jet means such that air flowing from said air jet means is operable to disturb said so they intermingle laterally to form an adhesive band on said first substrate across the entire pattern of said lines, and such that when air does not flow therefrom, said nozzle means produce beads for deposition in parallel lines; wherein, said first substrate is joined by said adhesive to another substrate, said adhesive bands block channels formed therebetween by said parallel bead lines.
 4. In an apparatus for applying adhesive to a substrate for adherence to another substrate wherein said adhesive is in a pattern of elongated straight lines of adhesive and intermittent bands of adhesive extending substantially transversely across and interconnecting said lines of said pattern, said apparatus including:a plurality of adhesive nozzle means for producing a plurality of emanating adhesive beads for deposition in a pattern of straight parallel lines on a first substrate; and air jet means in operative orientation with respect to said nozzle means for selectively impinging a flow of air on said emanating beads to disturb said beads so they intermingle laterally and to thereby form a band intermittently interconnecting said lines across said pattern.
 5. Apparatus as in claim 4 further including means to combine a second substrate onto said adhesive on said first substrate.
 6. In an apparatus for applying adhesive in varying deposition format to a substrate, for adherence to another substrate, so as to interrupt channels formed between said substrates by said format, said apparatus including:a plurality of adhesive nozzle means for producing a plurality of emanating adhesive beads for deposition in a pattern of straight parallel lines on a first substrate; air jet means in operative orientation with respect to said nozzles means for selectively impinging a flow of air on said emanating beads and for disturbing said beads such that they intermingle laterally and that said format comprises a plurality of elongated parallel lines of adhesive in the pattern intermittently interconnected to each other by adhesive bands extending transversely thereacross said pattern of straight parallel lines.
 7. Apparatus as in claim 6 wherein said air jet means are for forming an adhesive band emanating from said nozzle means and extending across said parallel lines of adhesive.
 8. In an apparatus for applying an adhesive pattern to a first substrate for adhering said first substrate to a second substrate said apparatus including:means for applying adhesive to said first substrate in the form of a pattern of spaced-apart, straight parallel adhesive lines, and means for disturbing said adhesive emanating from said applying means such that said adhesive intermingles laterally for thereby interconnecting said lines substantially transversely such that adhesive is deposited on said first substrate in a pattern of parallel lines intermittently interconnected by bands of adhesive transversely thereacross said pattern.
 9. Apparatus as in claim 8 wherein said disturbing means is for intermittently forming, from adhesive emanating from said applying means, bands of adhesive extending across and interconnecting said parallel lines in a substantially transverse direction.
 10. Apparatus as in claim 8 wherein said applying means further comprises means for intermittently intermingling said adhesive lines, prior to application to a substrate for joining said lines transversely and intermittently on said substrate.
 11. In an apparatus for adhering first and second substrates to each other with a pattern of parallel straight, lines of adhesive forming channels therebetween and between said substrate, said apparatus including:means for intermittently generating a disturbance in said adhesive prior to disposition on said first substrate to transversely intermingle and join said lines laterally together across said pattern with adhesive on said substrate, and to thereby block channels formed between said lines and said substrates, and means for adhering said substrates together with said adhesive in intermittently joined parallel line therebetween. 